Process of shaping rail-joint bars.



W. J'. BRADLEY.

PROCESS 0F Smm@ m11, 101m Mns.

APPLIOA'IMN FILED SEPT. 2%. 100B.

13994011614 Patentm Oct. 8, 1912.

7V. J. BRADLEY.

PROCESS 0F SHAPING RAIL JOINT BARS.

APPLICATION FILM SEPT. 24. 1908.

l ,040, 6 l 4, Patented Oct. 8, 1912.

5 SHBETS- SHEET 2.

fI//f ffl/fir W. J. BRADLEY.

momias, o? SHAPING RAIL JOINT BARS.

APILIUTIUN FILED SEPT. 24, 190B.

Pzteuw 01:1. 2%, 1912.

wif/ 22523 W. J. BRADLEY.

PROCESS UF SHAPING RAIL JINI BARSA APPLICAIION FILED SEPT. [1-1. 1908.

Patented. Oct. 8, 1912.

GSHEETSMSHEE'I' 4.

"UNTE idftrtlllliltd PAfllilNl OFFICE.

WILLIAM J. BRADLEY. 0F TROY, NEW YORK. ASIGNOR TO THE RAIL JOINT COMPANY, OF NEW YORK, N. Y., 'A CORPORATION OF NEW YORK.

PROCESS OF SHARING RAILJOINT BARS.

Specicatlon of Letters Potent.

aient ed Oel 8,1912.

Application tilccl September 24, 1908. Serial No. 454,550.

lle it known that I. Willman J. Hannan', t1 citizen of the United lStates, residing at Troy,- in the county of Rensselaer and State of New York. ha ".'e invented certain new and useful Improvements in lrtxresses of Shaping Rail-Joint Bars, of which the following is a specification.

This: invention relates to the subject ot' metal rt'illing, and has particularly in view certain novel and practical processes carried out by specially designed passes of a roll train t0 provide for the formation of rail ,joint bars of a special design.

To this end tht` invention contemplatesl improved and practical means or forming h the roll train of a rollin mill.' a rail' il' 'Joint angle har of the continuons type. hut

having a hase section of a width etplaling, or exceeding. the width of the hases of the rails, andl which base secticn therefore is intended to extend throughout the full width of the rails connected hy joint hars of this design.

In shaping the passes of a roll train for rolling a bar of the (.haracter above indicated, certain difficulties and problems have only been overcome h v careful calculation and experiment with the result of developing, by the present invention, a radically different pass formation from the pass formation ordinarily employed in the rolling of rail joint bars. lt is only by reason of the peculiar and special features of the new pass formation hucin claimed. that the modified continuous angle bar referred to can he properly formed. and it. will therefore he noted that the present invention provides a consecutive and complemental series et roll passes of s 1 h forni. dimension. and relation, as to provide for the progressive distribution and reduction of the metal. and the gradual-shaping of the har. in such a manner as to develop a finished product having the proper thickness, design. and weight, and otherwise having the necessary comnicrcial and trallic requirements fora' bar of the character referred to.

'ith these and other objects in view. wh'ich will appeal' to those skilled in the art as thc nature of thtl invention ishetter understcotl. thc sannccnsists in the novel con struction, ccmhinatiilin. and arrangement of parts hereinafter more fully described, illustrated and claimed.

The essential feature ot' the invention, in \ol\ed in the im|n-ovenunts embraced in the various passes. is necessarily `susceitihle to .some variations without departing 'l1-oui the scope of the in\ention as et forth in the appended claims. hut a preferred and practical emlmdiincnt thcrct't' is shown in the accompanying drawings. in which:

Figure l is a stcticnal chuation ol' those rolls of the complete train which are termed herein the primary reducing rolls, and are common-ly known as the hull rolls. is a similar view of those rolls ot the train termed herein the secondary development rolls, and commonly ltnown as the combina-- tion rolls. Fig. $5 is a similar view of the finishing rolls of the train. Figs. 4 to 13 inclusive are cross sectional views illustrative of the progressive development of the har as shaped by the various passes. Fig. 14 is a sectional perspective view of the special design of continuous angle hars, which is the product made by the present invention.

Like reference characters designate corresponding parts in the se\ eral figures of the drawings.

inasmuch as the iinprm'eineuts claimed herein. with respect to the peculiar form of the roll passes to provide for the proper progressive distribution and reduction of the metal. and the simultaneous shaping of the rail joint bar, are of special importance and utility in the manufacture of a modified design of continuous rail joint angle bar, the latter is shown for illustrative purposes in Fig. lt of the drawings. Referring thereto, it will be ohservtd that this design of angle bar is substantially lilce'the couventioi'ial and well I tnown form of continuous har with the exception that the base section of the modit'icd design shown in Fig. ll is of such a width as to extend throughout the full width ot' the rails from edge lo edge of the hase tlangcs thereof. Referring specifically t'o said inoditied design ot' continuous joint har, it may he observed that` the saine elnbndies therein an upright splice member l formed at its upper edge with a thickened bearing head '2 adapted to hear against the under side of the rail head. At the lower edge of the upright member or girder 1 the har body is formed with an outwardly extending foot ttange 3 adapted to overlie the hase flange of the rail, and having integrated with the outer edge poition thereof the integral horizontal rail supp'orting` hase section 4l, which. hase section may loe charactei-ized as a full. Width base section, inasmuch the saine extends beneath the leases this construction, which is produced by 'the proiierly spacing apart the several ring.;Y or' roll passes, provides for the Width of the metal of one side of said entrant groove being' two or more timesthe Width oit the inetal on the opposite side of the said -groove. Also, the said groove forms the upper and lower bearings of the rail flange, the bearing' in the said groove :for the loot- -toni of the base flange being two or more times the` hearing),l olthe top of the hase, Hangs.

ln carrying 'the invention into effect, it- Will he. understood that the several groups o' rolls 'may be mounted or arranged in any approved manner, accgnding to good rolling inill practice, and even the entireseries olf passes inav ce carried lley one set of rolls witlioutatlecting thepurpose of the present invention, lout in the. practi' leinhodirne-nt vof the latter Jdie roll t Iain, which is utilized in making the joint loar shown in Fig. lei ot the drawings, comprises the three sets of related and compleniental rolls-referred to, viz: the primary reducing` rolls, the secondary developingrolls, and, the finishing rolls. llroni a structural standpoint, and also in the matter ot the means provided forl the assembling and taking;` apart of the elements of the rolls, all of the saine are alike. that each ofi the rolls ol' eachset essentially comprises` a mandrel or shaft' li on which are detaeliablv sleeved in side by side relaW tion, a plurality oic :lie rings-or collars 'i'. the die faces o'l' which torni the Walls' the rolll passes hereinafter referred to. .iilso, each roll mandrel (3 aeconnnodates'tlieiecnu in connection with the :lie rings or collars 7 upon which are the working portions, tl e detachable filler and spacing' collars Sv and S respectively, which are utilized lfmfilillinn` the blank portions ol the rolls and also for collar elements. and permitting; the saine. to lie tightlyy clamped in position het-Ween. a suitable abutment or abutment shoulder l() on the mandrel, and a limiting unt ll in the torni of n' rinp; (leiagflialily engaging; a threaded section l of ille mai'ulrel. liv reason of this r iruetion-it will lie noted that the various ring or collar elements .torniiing' the Working parts lof the individual rolls .ln this connection, it to he noted` nose-,ere

may he readily removed and replaced, and arranged in any desired relative positions, as occasionl 'may require'. l

"lhe primary reducing rollsare arranged in a. set of three, in superposed relation, one above the other, and are designated. respectively hy the reference letters A, B and C, of the rolls and B, there is formed the initial pass l ot' the series. This initial pass l receives the har which may' or may not have been reduced to a suitable size capable of readily passing through said pass I, but for the purposes of the present invention, it will he iniderstoodthat the har as received hyy the said pass receives in the latter the first shape or form. which hears a definite relation tothe completed product which is to pass .l eilects an initiatory distribution of metal in the bar, and gives the Cross section of Fig. l o'fthe drawings.

Referringmore particularly to the formation ci' the initial pass, it ivill loe observed that. the. opposing pass Walls respectively in the rolls and B are similarly shaped, each of said pass AWalls having therein what may ne termed an intermediate rounded shaping groove '1.3, and convened reducing faces le at each side of said groove and merging into the same. v Said reducing faces terminate, at what may lle termed rtheir outer ends, in retaining shoulders l5 ttor checlringthe flow or" Athe metal in the direction of the interval be-I tween the non-working faces of the opposing rolls. lt has' been usually found necessary, ip tliecalculations with respect 'tothe proper` distribution oit thenietal, to have the shap-u ing groove 13 in the upper roll member B ci slightly greater depth than the eorre- --spending` shaping groove in the lovver roll member A', and the resultant bar section shaped hy the said pass l of the outline described, of the form shown in Fig. il. This initial shape of the bar rinay be characterized as thx starting form, and in Icross section "rnay he described a har lbody BX having; an intermediate thick Waist portion presenting projecting rounded swells 15 upon both sides thereof?, which swells correspond in the shape and extent or' project-ion to 'the oppositev shaping grooves 13 oit' the pass l. lnjaddition-to the thick Waist p0rtiou the harhody sliou'f'n in Figli is provided upon opposite sides of the Waist With the lateral tlf/inge portions 'i6 and 17 respectively, the'. lange portion ltlneing reduced thinner than the llange portion'l?. 'Tlie'har section. trenr gass lis nenti I1introduced into `passll4 u'hicli' is tormed'hetvveenopposing dies of the internediateroll and the top rollftl el said primary reducing" rolls, land in this Ayouoeclion7 il. will lie'oliserved thatthe upper the lower die for ll is ci." approxi- '.lio ol' pass Vl constitute;- oass Yll, ',llie. said pass and between the opposing dierings 7' iso match` the saine eontitruration as pasa I, and

the .aet-ondaiwi development' rolls, and is ditl'era4 therefrom prineipill't in its` width, l'ornied lit-tween opposing dies olE the lower as the oppowing wall.` l' the said pass ll are provided with the ir ertnrdiato shaping groores tit-tta the rontxeti. tattooing hietlL-ltl at the aides ot' raid groot/ea. and the retaininler hhoultler.- :il at the outer ends of tite fat-es ttt. lower grot'ive 123` ot' pasa II im materially greaterithan the upper groove 1 8 ot' the upper pti-a wall. (Rinsequently. the har aertior. which is rolled through the paas ll hetween the dieu forming` sueh part. receives It will he olisert'ed that the l a tliStinet reflui-tion in croma seetional area though preserving' the .aune rgeneral torina4 tion as thehar .sot-tion shown in Fig'. l. rl`he har seetion Ashaped h v pass ll i hewn in Fig. hut hy reason ol the shallownefts ot' the upper shaping?lr groove lit of the pasa lli. and-thc fart that the upper rtalueint,r tare.: 1.) of .said pass are approxiinaleltl tial. the hat' section ot. Vig. :3 i5 ont)Y lett with a slight swell projeetion Iii al, one :Aide` whihl the 'said side having said projeetion if; formed with approxiittatel)v flut tarel at one side otl the lateral flange portionn tti and ltl. the latter also heine redueed in thielcneua. The Awlitght swell projection 13 from the flat side lY 2l lot' the har `-eetioh ldiown in Fig, 5. :iets in the eapaeit ol' a presaitre rih l'or fort-iutr th' metal down into the hape ot' pasa lll. whit-h pasa i -.wonliued lit-tween opposing die` ol' the hottoni and intermediate rolla ai-d l) ot' the pri|uar ,wet ,-:hown in Fig. l. rllte upper pa, wall 22 oll pass III in atlhat'antial'tv llat throughout. and the af-tion tlf'reot' .wervento reduee the slight'` swell or projeetion 15 at one aide ol" the liar Shown in Vig. 5. while :it the aulne tinte the large .-well or projeetiou l5 at the opposite ot' tite sante har il'oreed downtt'ard into an approxiinatelty U-shaped hapin; r groove t i'n-orided in the lower pasa` wall ot' the pa` lll. 'l`lie .-ide ot' the groove 23 merge into the eonrrxed reducing .airfares 2l terniinatin; V at their outer edges iu the rotelle ing: I houlder 2f haringr the t'unetion ot' the shoulders l5 and ft) herein referred to. rlille har as lhaped hy the pass Ill hasl the forination `hown in Vig. ti, aaid form involving a further reduetion ol' the llange portiom iti and 1T and u more angular waist pto jeetion designated in Fig. ti hy the referente nuinher Lt. This waist projection is; arranged at the side of the har optiosite the flattened side or fat-e "2T lornted h v the upper pass all 'l`he primary reducing or hull rolls praetiealtv complete their tunti'tioua lu the produetion of the har Seetlon shown in Fig. t3. and thi.,` har .sseetionI is now taken up t 4)et'tion 2li :tt one ide ot the hat' hotly.

for tr Aatinent hy the seeondary develol'nnent rolls designated respeetit'ely h v the lettera D, ti. and l". and arranged in the saine relative positions ae the rolls A. li. and hel'ort: referred to. im l\' in the initial paw of and intermediate roll-; l) and ll. This pass ditlers t'roia pa llI principally iu the partit-:dar olI ;fi\in;.r niore definite shape, and lut-ther redurtion to the har section in Fig. t3. rpeeilirallt. the pass [Y is forint-d hetween a lower Straight pase: wall 2th and an opper pase rail having an aliproxiniately U-ahaped hapintr groove it having,r a more rounded latitoin than the corresptmtling groott- 122, ol pasI lll, und merging into niore ahruptlr eonvexed Iside retlueingr fue-es ltl teriuinathu.r at their outer edges in retainintr shoulders Ill and Irl reapeetively, the retaining.r hould -r Ztl serving to give more definite shape to the lateral tlange extension iT ol" the har hotly. while a corresponding t'unetiou if suhaerred hy the shoulder 32 with res-peet to tlte flange portion 16. Pas ll' produee the rhape lshown in Fig. 7.

'l'he redueed har aeetion of Fig. T is ret'eited within paxl V formed between the naine die that lornis the upper pass wall of pass IV. and a die of the upper roll F. ltenee. paw- V dill'erh` from pass IV in the partieular that the upper' pass wall is provided. slightly at one Hide of the vertical renter ot' the groove 2t), with a rounded tontruing projet-tion 33 whieh forms. in the tlat side i7 of the har hotly. a compensating deprtwion ZS--l whieh prevents an overflow ot' nietul between two rollrl in the edging paie; YI, See har section of Fig. 8. The edging pass VI marlta a radical and important Aatt-p in the progressive development of the har set-tion. as the pass wells of pass VI operate on the har etlgewise. the bar being entered through the pasa vertically. It will he ohaerved that the upper wall of the. pass VIy is t'orxned with an approximately rectan grular deep shaping: ILfroove 35. one side of wheli groove hun :i vertieal flat faire Siti. the opperhe side of whieli groove is of im obtuse angled forni, as inflieated at 37 to preaent an int-lined flatl redueing faee 38. 'the lower wall ot` the pasa Vl is corre- .-,p'-nlin;fl provided with an approximately reetanjjular deep hapin, y groove l!) having! :it one side u t'ei'tleal Hat fave 4t). and who 1e ether aide la of an ohtllse untled l'orniation to present an iut-lined tlat reduring! t'aee Atl eorrespondintr to the fat-e 3S. 'l`he groove 2V. is wider. though shallower. than the groove 135i .so that the l aid grooves reapeetirelt' ret-eiwand further redure the llauue portioml lt' and l? of thehai hotly. while the oppoaintr inelined wall faee 38 and Il gire a further reduetion to. and make :t well defined V'rhape f'or. the waird pro- This tti-ow. erlion olI hat' luidt' is allow!) lll Fig.

:t ol' 'he lrawingf.-. and it will he oherretl tluI .ronipeiimling' deprearlon ill iS ing, prevents an overow ot' metal between the opposing rolls, D and E.

It will be observed that the edging pass VI completes the shape of the waist projection 26. This waist projection, in the formation shown in Fig. 9, corresponds substantially to the external torin of the foot portion 3 ot' the completed bar shown in Fig. 14;, said foot portion including the adjoining part of the base section 4 which is integral therewith. Inasinucli as the said foot portion, embodied in the waist projection 26 of the barsection shown in Fig. 9, is completed after leaving pass VI, no further work is done on this part of the har, but a further development. and reduction ofthe latter for shaping purposes is carried out. in passes VII, VIIIl and IX, which are formed between the finishing rolls.

The rolls of the nated respectively Gr, VII is formed between of the intermediate and top rolls II and l'. The walls of the pass VII operate particularly on the tlange portions 16 and 17 of the bar body, and the thicker flange portion 17 receives in the pass VII the initiation 'of the shape for the upright member 1 and the head 2 of the finished product. lo this end 'the lower wall of the pass VII is formed with an .approximately lil-shaped seating groove 42 for the waist projection 26 constitutingthe toot projection or portion of the angle bar above specied.

43a for shaping the outside :ingle of the up .i right member and head of the bar section, and at the opposite side ot the groove 42,

the said lower pass wall is formed with a continuous convexed spreading ltace arranged .in parallelism to, and cooperating with, a complemented, conca'ved spreading face 44 formed in the lupper pass wall. In

addition to the face 44 the upper pass wall is formed with a tonguing projection 45 lying opposite the groove 42 in the lower pass wall, and at one side of which tonguing projection' the upper pass wall presents a shaping face 46 for the inside face of the upright member 'and head l and 2 of the or toot projection angle bar to be formed.

'It is to ybe particularly noted that pass VII not only initiates the shape of the upright nicn'iber and head .1 and 2l of the bar in lthe thicker tlange vportion 17 of the bar section shown in Fig. l), but also spreads ont, through the reducing action of the faces 48 and 44, thel thinner flange portion 16 into a. much widened `and thinner flange which is spread out to one side of the waist 26 on an easy, long curvo. Also, the tonguing projection or ril) 4-5 'lot the pass Vll initiates the entrantgroove 5 of the bar in one side thereof. These deinishing set are desig-` II, and I, and pass the opposing dies Also, the lower wall of the pass VII is formed at one side.

importance -in :income tails in the par format'mwmcn result'from p the act-ion of the passVII are plainly shown in Fig. 10 of the drawings. f

Pass VIIIv is formed between opposin'gilies of the rolls G and H, and pass IX betweenopposing diesof the rolls H and I. These two passes, however, are similar in design to pass V II, and hence, similar reference letters will apply to correspondingl arts in these several passes, the same only' differing particularly with respect to the dimension or size of the elements in order to get a progressive reduction of the metal in passes `VIII and IX. lAlso, the said similar passes differ noticeably in the graduated projection ot the tonguing part 4:5,"so that the entrant groove 5 may be tongued out to its full depth, as shown in the bar section of Fig. 12, which bar section is the result of,

the action of pass IX. Fig. llshows the bar section reduced by pass VIII.

Pass X is the inal pass and is constructed similarly to the several passes immediately preceding it, with the exception that in-V steadfo' the spreading' faces of the passes VII, VIII and IX, the corresponding portions 47 and 1&8 ofthe opposing pass walls are arranged' in straight lines, though obliquely to a vertical plane. Hence, the fares 47 and 48 of the pass walls 'of pass IX act as straightening faces for straightening out the widenediiange 16, whiehinakes the base section 4 in the completed bar. The

`bar section shown in Fig. 13 results from the action of pass X and leaves the base forming flange set obliquely orat anangl'e to the girder part which.' underlies the' head 'lot of the rail, but this part of the bar section is straightened out or other forming machine. In lfurther explanation of the pass X it will be observed that the tongue or projection 45 for this pass is provided with 'a narrowed tip that. cooperates with a 42.0flsaid pass to produce, final steps of ,the process,

as one of the the i clearance 4groove extension 5 at the bottoni of. the

flange receiving pocket or 4spacefY of the rail joint bar. rIrhis is a the production of .a modern rail joint bar which, includes a clearance beyond `the edge of the base flange of the rail.,

From the foregoing, it that the various passes provide and accurate rolling operation.while`at the same time securing such a progressiveV distribution and reduction of the metal and a gradual shaping of the bar as to insure the finished product-.having the proper design, thickness, and weight throughout, and also the construction and'arrangeinent of parts described permit of rolling out in a practical manner a continuous type of rail joint` angle bar having a double widthl base section, that is a base section extending beneath feature of practicaly by the ordinarybulldozing j shoulder 42 of the groove will be observed for an easy les the bases of the rails the 'foil width thereof, as hereinbefore pointed out.

l claim:

l. The process of shaping rail joint bars consisting in paesing a, bar blank through a roll pass to produce laterally projecting portions and an enlarged, waist portion projecting at .both sides, and then subjecting it to a series of passes which force the metal of the waist portion to one Side, `forming a substantially flattace on one side having a icompensating depression therein and an en-A larged portion on the other side.

2. The process of shaping' rail joint bars consisting in passing a bar blank thrtuigh a roll pass to produce laterally projectingl por tions, and an enlarged waist portion projecting at both sides, then subjecting it to a Series of passes which torce the metal ot' the waist portion to one side forming' a substantially flat lace on one .side with a. depression therein and an enlarged portion on the other side and then subjecting it to a pass which eliminates said (lepre w'ion and simultnne ously narrows the said enlarged portion at one side of the blank.

3. 'lhe proc-ees of shaping rail joint bars consisting in passing a bar blank through a roll pass to produce laterally projecting portions, and an enlarged waist portion projecting at both sides, and then .subjecting it to a series of passes which force the metal of the waist vportion to one side, andA to other passes which develop an entrant groove in the side oppoeite the enlargement at said Waist portion.

4. The process of Shaping rail joint bars consisting in passing a bar'blank through a roll pase to produce late ally projecting portiene and an enlarged 'waist portion pro-- jeeting at both sides, then subjecting it to a Series of passes which force the metal o'l the waist portion to o1 e sitlotjv forming an enlarged portion ther-eat, and then subjecting it to other paseea which develop an entrant groove in the side opposite the enlargement at the waist portion, and i'orm` a flat thinned section spread troni one of said laterally projecting portions.

5. The procesa oi shaping rail joint bars consisting in passing a bar blank through a roll pass to produce laterally projecting portions, and a waist portion projecting at both sides, then subjecting it to a series of passes which torce the metal of the waist portion to one sirlc, azul then subjecting it to other passes which develop an entrant groove in the side opposite the projection at the waist portion and. to l'orin a flat thinned section spread `from one of the laterally projecting portions, and a thicker member shaped from the other ot fsaiil. laterally projecting p0rtions.

t3. 'lhe prmfeuol ot" shaping rail joint bars (,:oneisting in passing a bar blank through a roll pase to produce laterally projecting portions, :intl a waist portion projecting at both nietes, then subject ing it to a serie: of passes which torce the metal of the waist portion to one siile, and then subjecting it to other passies which develop an entrant groove into the .aille opposite the enlargement at the waist portion, which produce a groove-extension at the bottom of said entrant groove, and 'torin a tlat thinned .section spread from one ot' the laterally projecting portions, and a thicker .splice member shaped from the other of the laterally projecting portions.

in testimony whereof I hereunto affix my .signature in the presence of two Witnesses:

WHQIJLM J. BRADLEY. Wi t [leases:

Bund. VoLnAUPrEn, WAL'reu S. OoiLvr. 

